User Manuals: Yamaha MX800V Multi-Purpose Engine

User Manuals: Yamaha MX800V Multi-Purpose Engine

Manuals and User Guides for Yamaha MX800V Multi-Purpose Engine. We have 1 Yamaha MX800V Multi-Purpose Engine manual available for free PDF download: Service Manual

Yamaha MX800V Service Manual

Yamaha MX800V Service Manual (158 pages)

Multi-Purpose Engines

Brand: Yamaha | Category: Engine | Size: 25.32 MB

Table of Contents

How to Use this Manual
5
General Information

7
- Table of Contents
  8
Machine Identification

11
- Serial Number
  11
- Starting Serial Number
  11
Dimensions

12
- Top
  12
- Mounting Base
  12
- Rear
  13
- REAR (for Models Equipped with a Muffler)
  13
- Right Side
  14
- RIGHT SIDE (for Models Equipped with a Muffler)
  14
Important Information

15
- Preparation for Removal and Disassembly
  15
- Caution on Service
  15
- Notes on Service
  15
- All Replacement Parts
  16
- Gaskets, Oil Seals, and O-Rings
  16
- Bearings and Oil Seals
  17
Basic Service Information

17
- Electrical System
  17
Special Tools and Testers

20
- Periodic Checks and Adjustments
  
  21
Introduction

21
Maintenance Intervals Chart

21
Periodic Maintenance/Lubrication Intervals

21
Periodic Maintenance

22
- Spark Plugs
  22
- Muffler
  23
- (For Models Equipped with a Muffler)
  23
- Engine Oil Leakage
  24
- Engine Oil Level
  25
- Replacing the Engine Oil
  26
- Fuel Leakage
  28
- Fuel Filter
  28
- Oil Cooler
  29
- Air Filter Element
  29
- Adjusting the Valve Clearance
  29
- Cylinder Heads Decarbonization
  33
- Engine Speed
  34
- Adjusting the Engine Speed
  35
- LOW ENGINE SPEED (Replace the Carburetor Assembly)
  36
- Fittings and Fasteners
  37
- Engine
  
  39
Engine Inspection

39
- Measuring the Compression Pressure
  39
Air Filter

41
MUFFLER (for Models Equipped with a Muffler)

42
Oil Cooler

43
- Removing the Oil Cooler
  44
- Checking the Oil Cooler
  44
- Installing the Oil Cooler
  44
Rectifier/Regulator

46
Case and Fan

47
Tci Units, Flywheel and Stator Coil Assembly

51
Cylinder Head Covers, Cylinder Heads

57
Valves

64
Oil Pump

70
- Disassembling the Oil Pump
  71
- Checking the Oil Pump
  71
- Checking the Relief Valve
  72
- Checking the Crankcase
  72
- Installing the Oil Pressure Switch
  72
- Assembling the Oil Pump
  73
- Installing the Crankcase Cover 2
  74
Pistons, Camshaft, Crankcase, and Crankshaft

75
Fuel Pump

95
- Checking the Fuel Pump
  96
- Fuel
  
  95
Carburetor Assembly

97
Intake Manifold

101
- Removing the Intake Manifold
  102
- Checking the Intake Manifold
  102
- Installing the Intake Manifold
  102
Circuit Diagram

104
- Electrical
  104
Electrical Components

106
- Checking the Switch Continuity
  108
- Checking the Oil Pressure Switch
  108
- Checking the Tci Unit Resistance
  108
- Notice
  108
- Checking the Ignition Spark Gap
  109
- Checking the Spark Plug Caps
  110
- Checking the Stator Coil Assembly
  110
- Checking the Rectifier/Regulator
  111
- Checking the Starter Motor Operation
  111
Electric Starting System

113
- Removing the Starter Motor
  113
- Disassembling the Starter Motor
  114
- Checking the Armature Coil
  115
- Checking the Brush
  116
- Checking the Starter Relay
  116
- Assembling the Starter Motor
  116
- Troubleshooting
  
  119
Engine Does Not Start

119
- Ignition System
  119
- Electric Starting System
  120
Other Troubles

121
- Engine Starts but Stalls
  121
- Engine Speed Does Not Increase
  122
- Engine Speed Is Uneven
  123
- The Battery Is Not Charged
  124
- Governor Operation
  125
Oil Pressure System

126
- Specifications
  
  127
General Specifications

127
Maintenance Specifications

129
- Engine
  129
- Electrical
  133
Tightening Torques

136
General Torque Specifications

136
Lubrication Points and Type of Lubricants

137
Wire Routing Diagram

138
- Upper Side View
  138
- Left Side View
  142
- Right Side View
  144
- Rear Side View
  150

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